Service Guide
319800-1
Pressure Control
Description and Operation
NOTE: The "Pressurtrol" pressure control
is designed to be used only on 70:1 ratio
grease pumps.
Model 319800-1 pressure control minimizes material
pressure drop that occurs when the pump cycles by
sensing material pressure to regulate air flow to the motor.
When material pressure is less than the pressure
setting of the control, the air valve opens and allows air to
the motor.
Once the material pressure reaches the control’s
pressure setting, the air valve closes.
Plumbing
WARNING
The pressure control requires highpressure tubing and fittings to connect to the
pump’s outlet. Never substitute or alter the
components that were equipped with the pump.
Personal injury can occur.
Package Models
The pump model usage for the pressure control is
indicated in Table 1.
Pump Model
Pump
Ratio
Air Motor
Model
Figure 1 Pressure Control Model 319800-1
(Shown with Typical Plumbing Accessories)
Specifications
Container Size
120 pounds (50 kg)
8540-A1, 8540-B
324400-5
8549-B1
400 pounds (180 kg)
70:1
9640
Air Inlet and
Outlet
Material Inlet
120 pounds (50 kg)
338066-A1
9649
400 pounds (180 kg)
Table 1
Pressure Control 319800-1 Usage
1/4 " NPTF (f)
Table 2
1/8 " NPTF (f)
Max. Air
Pressure
Max. Material
Pressure
psi
Bars
psi
Bars
200
517
7500
517
Pressure Control Model 319800-1 Specifications
Alemite Corporation
PO Box 473515, Charlotte, North Carolina 28247-3515
www.alemite.com
Copyright © 1998 by Alemite Corporation
670764
This document contains confidential information that is the property of Alemite Corporation
and is not to be copied, used, or disclosed to others without express written permission.
SER 319800-1
Revision (7-98)
SER 319800-1
Pressure Control
Air Vent
View of Figure
1
9
2
6
6
7
10
3
11
4
8
Weep Hole
5
12
AIR OUT
13
AIR IN
3
14
15
Point Groove
Downward
16
Figure 2
Revision (7-98)
Pressure Control Model 319800-1 - Exploded View
2
Alemite Corporation
Pressure Control
Item
No.
SER 319800-1
Part No.
Description
Qty
Notes
Numeric Order
Part # (Item #)
Extension
1
171000-4
Nut, Lock
1
311369
3
Retainer, Spring
2
317078
(2)
4
Spring
1
319801
(1)
5
Spring
1
319802
(5)
O-Ring, 7/32 " ID x 11/32 " OD
2
319803
(3)
7
Piston
1
319805
(10)
8
Body and Seat Assembly
1
319806
(13)
9
Piston Assembly
1
319812
(9)
10
Gasket (Fiber)
1
319815
(8)
11
Body
1
319816
(4)
12
Bushing
1
320297
(7)
13
Rod
1
321248
(14)
14
Washer (Leather)
1
321405
(11)
15
Packing, Block-V, 0.112 " ID x 0.348 " OD
1
321407
(12)
16
Adapter
1
324441
(16)
1
2
6
317078
171000-4
(6)
(15)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
Repair Kit
Part No.
Kit Symbol
398641-1
Description
Kit, Repair [Includes a 0.75 ounce (21.8 gm) tube of Magnalube-G Teflon grease]
The tube of Magnalube-G Teflon grease is part number 393590
Alemite Corporation
3
Revision (7-98)
SER 319800-1
Pressure Control
Lower Portion
IMPORTANT: Prior to performing any
maintenance procedure, the following safety
precautions must be observed. Personal
injury may occur.
6. Unscrew Adapter (16) from Body (11).
7. Remove Rod (13), Washer (14), and Block-V Packing
(15) from the Adapter.
WARNING
8. Remove Bushing (12) from the bottom of the Body.
Do not use halogenated hydrocarbon solvents such as methylene chloride or 1,1,1-trichloroethane in this pressure control. An explosion
can result within an enclosed device capable of
containing pressure when aluminum and/or zincplated parts in the pump come in contact with
halogenated hydrocarbon solvents.
9. Unscrew the Body from the Body and Seat Assembly.
• Remove Gasket (10).
10. Remove Piston Assembly (9) from the Body.
11. Remove O-Ring (6) from the Piston Assembly.
Clean and Inspect
Release all pressure within the system prior to performing any overhaul procedure.
• Disconnect the air supply line from the
plumbing of the pressure control.
• Into an appropriate container, operate the
control valve to discharge remaining pressure
within the system.
1. Clean all metal parts in cleaning solvent. The solvent
should be environmentally safe.
2. Inspect all parts for wear and/or damage.
• Replace as necessary.
3. Inspect Body and Seat Assembly (8), Piston Assembly
(9) and Rod (13) closely. Use a magnifying glass to
detect any score and/or wire draw marks.
• Replace as necessary.
Never point a control valve at any portion of your
body or another person. Accidental discharge of
pressure and/or material can result in injury.
4. Closely inspect the mating surfaces of all components
for any imperfections. Ensure a smooth and clean
contact is obtained when assembled.
Read each step of the instructions carefully. Make
sure a proper understanding is achieved before
proceeding.
Assembly
NOTE : Prior to assembly, certain components require lubrication in Magnalube-G
Teflon grease. Refer to Table 2 for details.
Overhaul
NOTE : Refer to Figure 2 for component
identification on all overhaul procedures.
IMPORTANT: Always use Magnalube-G
Teflon grease in this pressure control.
1. Install O-Rings (6) onto Piston Assembly (9) and
Piston (7).
Disassembly
Upper Portion
1. Secure the pressure control in a soft-jaw vise.
Item No.
2. Loosen Lock Nut (2) that secures Extension (1) to
Body and Seat Assembly (8).
• Unscrew the Extension from the Body and Seat
Assembly.
3. Remove Spring Retainer (3), Springs (4 and 5), and
additional Spring Retainer (3) from the Body and Seat
Assembly.
4. Remove Piston (7) from the Body and Seat Assembly.
1
Extension - External Threads
6
O-Rings, 7/32 " ID x 11/32 " OD
11
Body - Bore and External Threads
12
Bushing - Bore
14
Washer (Leather)
15
Packing, Block-V, 0.112 " ID x 0.348 " OD
16
Adapter - External Threads
Table 2
5. Remove O-Ring (6) from the Piston.
Revision (7-98)
Description
4
Lubricated Components
Alemite Corporation
Pressure Control
SER 319800-1
Lower Portion
1
2. Install and seat Block-V Packing (15) [lips
downward] into the top of Adapter (16).
3
5
3. Install and seat Washer (14) onto the Block-V
Packing and into the Adapter.
2
IMPORTANT: Make sure to point the
groove of Rod ( 13 ) downward. See
Figure 3.
8
4
4. Install Rod (13) [groove downward] into the
Washer and Block-V Packing.
3
5. Install Bushing (12) onto the Rod.
6. Screw the Adapter assembly into Body (11).
• Tighten the Adapter securely.
7
6
7. Install Piston Assembly (9) into the top of the
Body.
8. Install Gasket (10) onto the Body.
9. Screw the Body assembly into the bottom of
Body and Seat Assembly (8).
• Tighten the Body securely.
9
Upper Portion
10. Install Piston (7) [tapered end first] into the
Body and Seat Assembly.
6
11
11. Screw Lock Nut (2) all the way to the top of the
Extension.
10
12. Install Springs (4 and 5) onto each Spring
Retainer (3).
14
15
12
13. Install the Spring and Spring Retainer assembly
into Extension (1).
13
14. Screw the Extension completely into the Body
and Seat Assembly.
Groove
16
Installation
Figure 3
Pressure Control Model 319800-1 - Section View
WARNING
Do not mount this pressure control
on a pump with a ratio greater than 70:1.
Personal injury can occur.
Plumbing
Attach the pressure control to the pump’s air motor. Make
sure all the plumbing connections are secure.
Refer to Service Guide SER 8540-B or 9640 for details.
Alemite Corporation
5
Revision (7-98)
SER 319800-1
Pressure Control
Pressure Adjustment
Prior to Adjustment
Before the pressure control can be set, accessory
equipment is required as a text fixture. See Figure 4.
Setting the Discharge Pressure to 7500 PSI
NOTE : The following procedures consider
the pump ratio to be 70:1.
WARNING
1. Check to ensure Extension (1) is screwed completely
into Body and Seat Assembly (8).
Use high-pressure equipment to check the
discharge pressure of the pump.
2. Turn the Extension counterclockwise 6-turns out of the
Body and Seat Assembly. See Figure 4.
The use of components that are not rated as highpressure can cause personal injury.
3. Attach an air line to the air coupler.
4. Set the air pressure regulator to a minimum of
150 psi (10.3 Bars).
• Do not exceed 200 psi (13.8 Bars).
• Inspect the vent for air leakage. See Figure 2.
1. Install the text fixture to the adapter of the pump outlet
as illustrated in Figure 4.
• Make sure all connections are secure.
5. Allow the pump to stall.
• Inspect the weep hole for product leakage.
2. Make sure High-Pressure Shut-Off Valve (b) is closed.
3. Place the pump in the product to be dispensed.
If the pump does not prime and/or adequately stall,
refer to the Troubleshooting Chart in SER 8540-B.
Turn Extension
Outward Six (6) Turns
from Fully Seated Position
d
40
00
0
20
00
a
0
60
8
00 000
40
00
10
00
0
10
00
0 2
00
12
00
0
0
0
14
00
0
15
00
0
10
10
00
00
e
b
c
f
g
Item Part No.
No.
a
Description
Item Part No.
No.
Qty
Description
Qty
Elbow, Street, 1/2 " NPTF (m)
1
e
309727
Tee, High-Pressure, 1/4 " NPTF (f)
1
b
308785
Valve, Shut-Off, High-Pressure, 1/2 " NPTF (f)
1
f
327033
Adapter, High-Pressure, 1/4 " NPTF (m)
1
c
130552
Adapter, H-P, 1/4 " NPTF (m) x 1/2 " NPTF (m)
1
g
40996
Bushing, H-P, 3/8 " NPTF (m) x 1/4 " NPTF (f)
1
d
317150
Gauge, H-P, [0-15,000 psi (0-100,000 kPa)]
1
Figure 4
Revision (7-98)
High-Pressure Accessory Equipment for Setting Pump Discharge Pressure - Test Fixture
6
Alemite Corporation
Pressure Control
SER 319800-1
Cut-Out Pressure
7. Place an appropriate collection container at the
opening of the High-Pressure Shut-Off Valve.
6. Record the reading on the pressure gauge.
8. Slowly open the Shut-Off Valve and allow the pump to
cycle.
IMPORTANT: Do not exceed the rating of
7500 psi (517 Bars).
9. Close the Shut-Off Valve.
The gauge should read between 7000 and 7500 psi
(483 - 517 Bars).
10. Repeat steps 5 through 9 until the value on the gauge is
within limits.
If the value on the gauge is too high, loosen the
Extension from the Body and Seat Assembly.
Cut-In Pressure
Conversely, if the value is too low, tighten the
Extension into the Body and Seat Assembly.
11. Slowly open the Shut-Off Valve once again.
12. Once the pump begins to cycle, record the reading on
the pressure gauge.
IMPORTANT: One full turn of the Extension
equates to approximately 200 psi (13.8 Bars).
The gauge should read between 6000 and 6400 psi
(413 - 441 Bars).
WARNING
If the value on the gauge is not within limits, refer to
the Troubleshooting Chart.
Never point the test fixture outlet at any
portion of your body or another person. Lubricant
discharged at high velocity can penetrate the skin
and cause severe injury. Should any fluid appear to
puncture the skin, get medical care immediately.
13. Tighten Lock Nut (2).
Open the High-Pressure Shut-Off Valve slowly.
Personal injury can occur.
Troubleshooting Chart
Pressure Control Indications
Possible Problems
Solution
Cut-Out pressure not
obtainable
1. Pressure control leaking externally
2. Worn or damaged Piston Assembly (9)
3. Worn or damaged bore in Body (11)
4. Pump leaking internally
5. Pump leaking externally
1.
2.
3.
4.
5.
Cut-In pressure not obtainable
1. Worn or damaged Spring(s) (4 and/or 5)
2. Worn or damaged Piston (7)
3. Worn or damaged bore in Body and Seat
Assembly (8)
1. Replace Spring(s) (4 and/or 5)
2. Replace Piston (7)
3. Replace Body and Seat Assembly (8)
See External Product Leaks
Replace Piston Assembly (9)
Replace Body (11)
See SER 8540-B
See SER 8540-B
External Product Leaks
Product visible at weep hole in
Body (11)
1. Worn or damaged Block-V Packing (15) 1. Replace Block-V Packing (15)
2. Worn or damaged Rod (13)
2. Replace Rod (13)
External Air Leaks
Air felt at vent in
Extension (1)
Worn or damaged O-Ring (6)
Replace O-Ring (6)
Changes Since Last Printing
Initial Release
Alemite Corporation
7
Revision (7-98)
SER 319800-1
Revision (7-98)
Pressure Control
8
Alemite Corporation